Introduction to MPR (Material Requirement Planning)

MRP is a simple system of calculating arithmetically the requirements of the input materials at different points of time based on actual production plan. MRP can also be defined as a planning and scheduling system to meet time-phased materials requirements for production operations. MRP always tries to meet the delivery schedule of end products as specified in the master production schedule.

MRP Objectives

MRP has several objectives, such as:

Reduction in Inventory Cost: By providing the right quantity of material at right time to meet master production schedule, MRP tries to avoid the cost of excessive inventory.

Improved Performance: By stream lining the production operations and minimizing the unplanned interruptions, MRP focuses on having all components available at right place in right quantity at right time.

MRP System

A simple sketch of an MRP system is shown in figure. It can be seen from the figure that an MRP system has three major input components:

Fig.
Material Requirements Planning System Architecture

Master Production Schedule (MPS): MPS is designed to meet the market demand (both the firm orders and forecasted demand) in future in the taken planning horizon. MPS mainly depicts the detailed delivery schedule of the end products. However, orders for replacement components can also be included in it to make it more comprehensive.

Bill of Materials (BOM) File: BOM represents the product structure. It encompasses information about all sub components needed, their quantity, and their sequence of buildup in the end product. Information about the work centers performing buildup operations is also included in it.

Inventory Status File: Inventory status file keeps an up-to-date record of each item in the inventory. Information such as, item identification number, quantity on hand, safety stock level, quantity already allocated and the procurement lead time of each item is recorded in this file.

After getting input from these sources, MRP logic processes the available information and gives information about the following:(Output Of MRP)

Planned Orders Receipts: This is the order quantity of an item that is planned to be ordered so that it is received at the beginning of the period under consideration to meet the net requirements of that period. This order has not yet been placed and will be placed in future.

Planned Order Release: This is the order quantity of an item that is planned to be ordered in the planned time period for this order that will ensure that the item is received when needed. Planned order release is determined by offsetting the planned order receipt by procurement lead time of that item.

Order Rescheduling: This highlight the need of any expediting, de-expediting, and cancellation of open orders etc. in case of unexpected situations.